Frame Setup & Installation Instructions Chevrolet 3100

Transcription

1 Frame Setup & Installation Instructions Chevrolet 3100 ART MORRISON ENTERPRISES, INC TH STREET EAST FIFE, WASHINGTON, (800) (253) FAX (253)

2 2 Table of Contents Introduction... 3 Body Mounting... 3 Engine Fitment... 4 Transmission Fitment... 4 Steering Column & Linkage... 4 Brake Pedals & Lines... 5 Wheels & Tires... 5 Axle Housings... 5 Frame Fit and OEM Tolerances... 5 Frame & Component Installation & Setup... 6 Alignment Specifications... 7 Post-Drive Checklist Chevrolet 3100 Wheel Size and Offset Specs mm Front/255mm Rear High Height Tire Example mm Front/295mm Rear Low Height Tire Example Important: Lifting a Vehicle with Two-Post Lifts Steering Rack Technical Information DSE/Mustang Rack Steering Stop Information Rear Coilover Installation Rear Sway Bar Installation Front Sway Bar Installation Front Lower Control Arm Installation Front Upper Control Arm Installation Ball Joint Cap Installation Optional Equipment: Stainless Brake Line Kit (High Height Models) Optional Equipment: Stainless Brake Line Kit (Low Height Models) Optional Equipment: Brake Proportioning Valve Mount Kit Optional Equipment: Brake/Clutch Pedal Assembly Instructions Optional Equipment: LS Polyurethane Motor Mount Kit Optional Equipment: LS Rubber Motor Mount Kit Optional Equipment: Axle Housing Vent Kit Fastener Information & Torque Specifications ART MORRISON ENTERPRISES, INC TH STREET EAST FIFE, WASHINGTON, (800) (253) FAX (253)

3 3 Introduction Congratulations on the purchase of your Art Morrison Enterprises GT Sport chassis. This frame is the result of many years of chassis and suspension design experience. In an effort to make your project progress smoothly, we have compiled this booklet containing instructions, notes and tips on removal of your current frame as well as assembly and installation of your new GT Sport chassis. Art Morrison Enterprises Engineering department has developed an entirely exclusive design that provides superior geometry with the Wilwood Pro Spindle. Countless hours were spent utilizing computer modeling and analysis to ensure the suspension provided on this frame provides excellent performance yet fits the packaging necessary Ford pickups. The GT Sport frames follow the Art Morrison design philosophy that combines simplicity and elegance. We believe stiffening material and bracing should only be added as necessary because too much only leads to additional weight. High stiffness can be obtained by geometric design and strategic placement rather than adding material. The Chevrolet 3100 GT Sport chassis uses a fully boxed 2x6 mid-rail section with strategically placed bracing further increases torsional stiffness. Connected to the 2x6 mid-rail is mandrel-bent wall 2 x4 material made specifically for Art Morrison Enterprises. Body Mounting The Art Morrison GT Sport chassis is a bolt-on frame, meaning it bolts to the body as the original frame did. Please refer to a factory assembly manual for removal and assembly instructions. Typical body mount kits are made of rubber and are widely available for 3100 s and any kit produced for a stock chassis will work on a GT Sport frame. Body mounts can vary by material, from soft materials such as rubber to harder materials such as aluminum. All material options have their merits. Rubber body mounts can isolate vibrations and offer a quiet cabin, similar to modern cars. These mounts however, act as a secondary spring between the suspension and body and add body flex. People looking for a quiet, vibration free cabin should look into using rubber mounts. Those who are looking for performance or running tight fender gaps should use harder materials. Polyurethane and aluminum mounts can be grouped into the same category as their compressed stiffness is fairly similar. Polyurethane mounts will isolate high frequency vibrations (which cause high pitched rattles) ART MORRISON ENTERPRISES, INC TH STREET EAST FIFE, WASHINGTON, (800) (253) FAX (253)

4 4 slightly better than aluminum. However, aluminum mounts have the advantage of being highly accurate and are ideal for high performance vehicles or those with tight fender gaps. Because of the zero compressibility of aluminum mounts, consider running medium strength thread locker on the body bolts. The Chevrolet 3100 GT Sport chassis is available in both low and high ride height configurations. Low ride height trucks will use 2 front drop spindles and require the bed floor to be raised 3. High ride height trucks will use standard height front spindles and require no bed modifications. Engine Fitment Your new GT Sport frame will accept small block, big block and LS-series Chevrolet engines. For proper fitment LS engines require the use of adapter plates available only from Art Morrison Enterprises; the utilization of adapter plates from other manufacturers may generate clearance issues. LS F-Body engine accessories (including A/C compressors) will typically fit within the frame rails. Corvette, GTO, CTS and truck accessory configurations will also fit. When shopping for an aftermarket drive system, pay particular attention to the area left of the engine oil pan as this is where the steering rack will reside. The engine oil pan design is critical for proper performance as well as trouble-free installation. Due to the steering rack location, oil pans typically will need to have a minimum front depth. For small and big blocks, traditional front pan depths (similar to stock) will be adequate. For LS engines, choose a pan that is similar to a F-Body or LS2/LS3 oil pan. For reference, front pan depths should be around 1-7/8. Transmission Fitment The GT Sport frame is designed to support modern manual and automatic transmissions. Manual transmissions will require the use of a hydraulic throwout bearing which is made easy by an available hydraulic clutch pedal kit from Art Morrison Enterprises. Due to the size of modern transmissions, there is a possibility of requiring the transmission tunnel to be modified. Steering Column & Linkage The stock 3100 steering column is directly connected to the steering box therefor it is good practice to use an aftermarket column. An aftermarket steering column should be utilized for several reasons. First, the column can be ordered in any length for maximum flexibility. Second, the welcome addition of a tilt feature and all new components as well as zero steering shaft radial play makes these columns a convenient choice. Third, they feature a 1 double-d end for easy linkage hook-up. A steering linkage kit that provides you with all the necessary parts to connect an aftermarket column to the steering rack is available from Art Morrison Enterprises. ART MORRISON ENTERPRISES, INC TH STREET EAST FIFE, WASHINGTON, (800) (253) FAX (253)

5 5 Brake Pedals & Lines Art Morrison Enterprises offers a brake pedal assembly and pre-bent stainless brake lines. The available Chevrolet 3100 brake pedal assemblies accommodate builds with automatic or manual transmissions. Those using manual transmissions will utilize a Wilwood Compact Remote master cylinder (3/4 bore typical) with a 6:1 ratio. Brake hydraulics are accomplished with a 6:1 pedal ratio and the optional use of a 7 or 8 power booster. Both brake and clutch pedals can be shimmed side-to-side for optimal placement in the floor plate. Art Morrison Enterprises stainless steel brake line kits connect directly to the proportioning valve included with the pedal assembly to make plumbing easy. The brake lines are made from 304 stainless and utilize -03AN stainless fittings. Wheels & Tires While the GT Sport s hub track is similar to stock, there are other considerations to examine before using wheels for a stock chassis. First, the brakes used on a GT Sport chassis requires close attention regarding overall diameter and caliper offset. Second, the chassis will lower the car much more than stock and typically will require slightly more positive offset. While Art Morrison Enterprises has gone to great lengths to ensure proper wheel and tire fitment, variations can occur from vehicle assembly or modifications/repairs over the years that affect fitment. Backspacing and proper fitment should be double checked before ordering wheels! The rear inner fenders limit the truck s ability to accept wide tires. Without fabricated wheel tubs, only a 255mm tire will fit, but the bed must be precisely square to the frame. Up to a 295mm tire will fit with a 2 widened wheel tub. In front, 285mm front tires will require steering stops or tire rubbing may occur. Axle Housings When ordering a GT Sport frame, several axle housing options are available. To make selection simple the housing width can be specified to replicate stock (about 60 wheel mount width), 2 narrow, or a custom width. All axle housings are a modern rendition of a Ford 9 design. These housings include a brand new stamped center section (Fab 9 is optional), 3 diameter 3/16 wall axle tubes, and forged tube ends. All housings are built on a precise fixture that ensures proper wheel alignment. Frame Fit and OEM Tolerances Art Morrison Enterprises has done extensive testing to ensure the frame matches OEM specifications while maintaining much tighter tolerances than Ford s specifications as produced over 60 years ago. Over the years, these vehicles have been subjected to high miles, accidents, racing and lastly, time. Many of these vehicles have been in accidents but the damage from which is no longer readily evident, however these incidents may have severely distorted the location of body mounts. Even low mileage, pristine survivor cars ART MORRISON ENTERPRISES, INC TH STREET EAST FIFE, WASHINGTON, (800) (253) FAX (253)

6 6 can suffer from body sag due to uneven spring settling. Due to these factors, the body mounts located on the frame may be slightly different than those on the body shell. This is considered normal, and is often not an issue thanks to a large amount of adjustability. When fitting the frame to the body, shimming the body mounts is recommended if a precise fit is desired. Frame & Component Installation & Setup Frame removal and installation follow identical procedures between the stock frame and GT Sport frame. Refer to the factory shop manuals for procedures and torque settings. Prior to assembling the frame to body, all brake lines, fuel lines, parking brake cables, etc. should be attached. To prevent interference later, it is imperative to be mindful of where the engine and headers will sit. Prior to finishing, the frame should be disassembled. As the frame is assembled at Art Morrison Enterprises the front and rear suspension is pre-set to initial alignment specifications as a quality check. To maintain these settings, prior to getting the car aligned, be sure to take measurements of upper control arm shims and tie rod lengths. Ideally, all welding and drilling should be completed prior to powdercoating or painting. Please note that all welds must not be ground smooth as this will weaken the frame s structural integrity. If you wish to have the welds smoothed use body filler instead. After the finishing operation has been completed the frame can now be assembled. Set the frame on a level surface in a well-lit area. Next, use a rat-tail file to clean all holes which bolts pass through and make sure all threaded bosses are clear of powder or paint. To finish the preparation process, collect all fasteners and have the torque specifications sheet handy. To begin assembling, install the upper control arm/knuckle/lower control arm assembly by first fastening the lower control arm bolts to the frame. Next, bolt the upper control arm to the frame ensuring that the alignment bushings lay between the two. Hand-tighten all fasteners for now and repeat the process on the opposite side. Now, install the steering rack with the fasteners, hand-tighten and attach the tie rod end to the knuckle. To install the sway bar, first attach the end linkage to the bar using the drawing as a guide. Then attach the linkage to the control arm and rotate the bar toward the bottom of the frame for attachment. To mount the coilovers, attach the lower mount to the control arm with the provided fasteners and then attach the upper mount to the chassis. As a starting point, set the coil spring adjuster to 1 above the lowest adjustment point. When plumbing the steering rack, note the fitting closest to the radiator is the pressure line and the other is the return. To start the bleeding process, first fill the reservoir full of power steering fluid. With the reservoir cap removed and the wheels off the ground, turn the steering wheel lock-to-lock twenty times while monitoring the fluid level. When complete, the engine can be started and checked for leaks. Before driving for the first time, rotate the steering wheel another four times. See the Steering Rack Technical Guide later in this manual for other important information. ART MORRISON ENTERPRISES, INC TH STREET EAST FIFE, WASHINGTON, (800) (253) FAX (253)

7 7 To complete the assembly process attach any brake lines, brackets, transmission crossmember and other necessary components. Check every fastener for proper torque and mark with a paint pen as a visual indicator. If you purchased the optional Wilwood brake kit it is imperative the break-in procedure be followed very carefully. Failure to follow these directions will lead to glazed pads and poor braking performance. If these directions are missing from your brake kit, visit to download their instructions. Street Settings: Toe: 1/32 to 1/16 total (in) Camber: ½ to ¾ degree negative Caster: 6 degrees positive Alignment Specifications Autocross Settings: Toe: 0 to 1/16 total (out) Camber: 1-3/4 degree (Consult tire manufacturer) Caster: 6 degrees positive Road Course Settings: Toe: 0 to 1/32 total (in) Camber: 1-1/2 degree negative (Consult tire manufacturer) Caster: 6 to 7 degrees positive Post-Drive Checklist After the first 100 miles, please check these items: 1. All fasteners (including wheel lugs) 2. Brake fluid (Fluid level and check fittings for leaks) 3. Power steering fluid (Fluid level and check fittings for leaks) 4. Coolant (Fluid level and check fittings for leaks)) 5. Transmission fluid (if applicable) 6. Fuel lines (Check fittings for leaks) 7. Brake Lines (Check fittings for leaks) 8. Battery cables 9. Exhaust system The coil springs should also be checked and readjusted if necessary. New springs will typically settle once after several miles and usually do not need a second adjustment. ART MORRISON ENTERPRISES, INC TH STREET EAST FIFE, WASHINGTON, (800) (253) FAX (253)

8 Chevrolet 3100 Wheel Size and Offset Specs Rear Wheel Dimensions With a bare housing width shown below, the rim width and backspace dimensions that will fit correctly are as follows: Housing Width 54-1/2" 52-1/2" Max Rim Width: 12" 12" Max Section width: 13-1/2" 13-1/2" Backspace: 7" 6" Other sizes: 255mm on 9 wide rim with 4" (54-1/2 HSG) / 3" (52-1/2 HSG) B.S. 275mm on 10" wide rim with 5" (54-1/2 HSG) / 4" (52-1/2 HSG) B.S. 295mm on 11" wide rim with 6" (54-1/2 HSG) / 5" (52-1/2 HSG) B.S. Front Wheel Dimensions Caution! Front rim backspace will depend on brake choice. Please finalize your brake choice before purchasing wheels! Wilwood 11" and 12.19" brake kits: 10" wide rim with 5-1/2" backspace 9" wide rim with 4-1/2" backspace 8" wide rim with 3-1/2" backspace Wilwood 13" and larger brake kits: 10" wide rim with 6" backspace 9" wide rim with 5" backspace 8" wide rim with 4" backspace ART MORRISON ENTERPRISES, INC TH STREET EAST FIFE, WASHINGTON, (800) (253) FAX (253)

9 255mm Front/255mm Rear High Height Tire Example ART MORRISON ENTERPRISES, INC TH STREET EAST FIFE, WASHINGTON, (800) (253) FAX (253)

10 10 275mm Front/295mm Rear Low Height Tire Example ART MORRISON ENTERPRISES, INC TH STREET EAST FIFE, WASHINGTON, (800) (253) FAX (253)

11 Important: Lifting a Vehicle with Two-Post Lifts The debate of choosing a four or two post lift is something that many can have strong opinions about. While driving the vehicle onto a four post lift is convenient, it comes at a cost of requiring another lifting assembly to raise the vehicle off of the ramps in order to remove the wheels and perform any brake or suspension work. Two post lifts solve this problem by lifting the vehicle by the frame or reinforced unibody structures. However, the problem will arise with a two-post in which the vehicle is lifted unnaturally, meaning loads are placed in areas that will cause some beaming flex. This type of flex is a function of frame stiffness and body stiffness, with the frame stiffness is typically 30-40% of the total beaming stiffness. Vehicles with heavy drivetrains will increase flex, as the majority of this weight (engines and axle housings) are far away from the lifting points. It should be noted that this flex is completely normal. Dealerships and OEMs use two posts lift which should be a testament to their safety. However, this issue can become a problem with vehicles with precision door gaps that are tighter than typical OEM specifications or body panels that have been modified or removed for larger engines, aesthetics, etc. Panels and doors should always be fitted with the vehicle on the ground or the frame properly supported in some way. Convertibles will always see much more flex than coupes and sedans, to the point that doors may not open or shut. In most cases, the older the vehicle, the higher probability for flex as body stiffness increased with newer vehicle designs with more stringent safety standards. While beaming flex may be alarming to some people, this does not mean the vehicle won t drive correctly. As mentioned before, it s simply loading the vehicle in an unnatural way. Vehicles are meant to be driven with the normal road force applied to the vehicle s suspension, not applied to the area below the rocker panels. Loading the vehicle properly allows the forces to be efficiently transmitted through bracing and body panels with the upper areas in compression, whereas loading at the rocker loads these areas in tension with the drivetrain and suspension acting as ballast which encourages flex. In summary, beaming flex is a normal occurrence when using two post lifts. Vehicles of all types, new or old, full frame or unibody, coupes/sedans and convertibles, will flex. The magnitude of this flex depends on vehicle age, condition, construction, design, drivetrain weight, and lastly the lifting point spread all of which is to be expected. ART MORRISON ENTERPRISES, INC TH STREET EAST FIFE, WASHINGTON, (800) (253) FAX (253)

12 12 Steering Rack Technical Information Hoses For those using -06AN hoses, AME can supply the proper fittings. Be aware that some aftermarket fittings do not use the correct threads and can damage the casting. Before installing, coat the O-ring with power steering fluid and torque the fitting to 20 lb-ft. The return hose can be any type of low-pressure hydraulic hose. The pressure hose can exhibit pressures above 1500PSI and requires a high pressure hose. We do not recommend the use of any stainless steel braided/teflon lined hose for its inability to dampen hydraulic chatter, thus creating a growl sound when turning the steering wheel. To keep this noise to a minimum, use a hose with a rubber length of 15 or more. The pressure fitting on the rack casting is the fitting closest to the front of the vehicle (lower fitting), and the return fitting is the closest to the firewall (upper fitting). Rack Centering It is easier to center the steering rack before mounting the unit to the chassis. To center the rack, turn the pinion to full lock and measure between any point on the rack body to the end of the tie rod in the extended direction. Divide this distance by two, and rotate the pinion in the opposite direction until this distance is reached. The rack is now centered. Using a paint pen, mark the pinion s location on the seal or housing so the rack can be re-centered if moved later. Mounting All Mustang-type steering racks mount using 5/8 -NF x 3.5 bolts when using an Art Morrison chassis. Be sure to liberally coat the threads with anti-seize before installing. Torque bolts to 50 lb-ft. When using rebuilt steering racks, end boots may be loosened and rotated to move the 3/16 equalizer tube to a different location if more clearance is needed. Tuning Both steering racks respond well to fluid flow rates between 2 to 3 gallons per minute. Less flow tends to increase steering effort, but too little may lead to pump catch where power steering assist momentarily stops until the pump can catch up to the required fluid flow. Too much flow may lead to a steering feel that is too light and possibly twitchy. Some power steering pumps have adjustable flow rates, while most OEM type pumps do not. If you feel the fluid flow rate may be too high, contact Art Morrison Enterprises for a valve that will allow approximately 2 gallons per minute of fluid flow. ART MORRISON ENTERPRISES, INC TH STREET EAST FIFE, WASHINGTON, (800) (253) FAX (253)

13 13 Keep in mind that pumps originally used for steering boxes typically have higher pressure and flow rates than what is required for steering racks. If your pump provides too much pressure, fluid may escape past seals in the steering rack and cause a failure, particularly with rebuilt steering racks. Art Morrison Enterprises has a pressure reducing kit to correct these situations. For cars using wide tires, Art Morrison Enterprises can supply steering stops that snap on to the rack shaft with the boots removed. This provides a simple way to limit steering travel for cars with interference issues. Bleeding Procedure (Important! Do not skip this procedure!) 1. Place the front end of the vehicle on jack stands and remove drive belt. 2. Fill reservoir with high quality power steering fluid and rotate the pump pulley by hand for about thirty seconds. 3. Have a second person rotate the steering wheel from lock to lock, about thirty times, while continuing to rotate the power steering pump pulley by hand. Watch the fluid reservoir to make sure it does not run dry. 4. Install the drive belt and start the engine. Continue to rotate the steering wheel from lock to lock about fifteen times while the engine idles. Watch the fluid reservoir to make sure it does not run out of fluid, or appear foamy. If foam does appear, shut off the engine and restart the bleeding process. 5. When fluid appears free of foam, top off the reservoir and check for leaks. This lengthy bleeding process will ensure the majority of the air is removed before initial startup to prevent pump damage and provide trouble-free steering. Steering Rack Specifications Rebuilt DSE Standard Width DSE Narrow Width Inner Ball Width Rack Travel (approx.) Turns lock-to-lock Tie Rod Thread Size 9/16-18 Input Shaft Spline ¾ -36 Fluid Flow Rate GPM 2.0GPM 2.0GPM Peak Pressure 1200PSI 1800PSI 1800PSI Pressure Fitting 9/16-18 Return Fitting 5/8-18 ART MORRISON ENTERPRISES, INC TH STREET EAST FIFE, WASHINGTON, (800) (253) FAX (253)

14 14 DSE/Mustang Rack Steering Stop Information Steering Limiter Maximum Size (in) Steering Angle* / / / ¼ / / / This guide is specific for a C6 suspension using the new steering arm, which is most likely to have wide tires and wheels installed. However, for Pro Spindle based suspensions, the results are similar. To install the limiter, roll the rubber boot away from the rack body and snap the plastic clip into place. *Note: This angle represents the outside wheel when in a turn. The forward edge of the inside wheel moves away from the frame and suspension, which negates any contact problem. When Ackerman is considered, the actual maximum steering angle is 33 degrees. ART MORRISON ENTERPRISES, INC TH STREET EAST FIFE, WASHINGTON, (800) (253) FAX (253)

15 15 Rear Coilover Installation ART MORRISON ENTERPRISES, INC TH STREET EAST FIFE, WASHINGTON, (800) (253) FAX (253)

16 16 Rear Sway Bar Installation ART MORRISON ENTERPRISES, INC TH STREET EAST FIFE, WASHINGTON, (800) (253) FAX (253)

17 17 Front Sway Bar Installation ART MORRISON ENTERPRISES, INC TH STREET EAST FIFE, WASHINGTON, (800) (253) FAX (253)

18 18 Front Lower Control Arm Installation ART MORRISON ENTERPRISES, INC TH STREET EAST FIFE, WASHINGTON, (800) (253) FAX (253)

19 19 Front Upper Control Arm Installation ART MORRISON ENTERPRISES, INC TH STREET EAST FIFE, WASHINGTON, (800) (253) FAX (253)

20 20 Ball Joint Cap Installation ART MORRISON ENTERPRISES, INC TH STREET EAST FIFE, WASHINGTON, (800) (253) FAX (253)

21 21 Optional Equipment: Stainless Brake Line Kit (High Height Models) Rev0 MJ 05/13/

22 Rev0 MJ 05/13/

23 Rev0 MJ 05/13/

24 Rev0 MJ 05/13/

25 Rev0 MJ 05/13/

26 Rev0 MJ 05/13/

27 27 Optional Equipment: Stainless Brake Line Kit (Low Height Models) Rev0 MJ 05/13/

28 Rev0 MJ 05/13/

29 Rev0 MJ 05/13/

30 Rev0 MJ 05/13/

31 Rev0 MJ 05/13/

32 Rev0 MJ 05/13/

33 33 Optional Equipment: Brake Proportioning Valve Mount Kit Rev0 MJ 05/13/

34 34 Optional Equipment: Brake/Clutch Pedal Assembly Instructions Chevrolet Pickup Brake/Clutch Pedal Assembly Instructions PN (Automatic Trans.) / (Manual Trans.) The Art Morrison Enterprises brake & clutch pedal assembly for Chevrolet pickups is an all new design utilizing permanently lubricated precision bushings and preload springs to reduce pedal vibration. This innovative design allows the use of a Wilwood Compact Remote master cylinder (3/4 bore recommended) for hydraulic clutch applications. The brake master cylinder mounting plate is a dual pattern design that allows for Mopar or GM type master cylinders, as well as the common Bendix power booster stud pattern. Due to space limitations, only 7 power boosters may be used. It is assumed the pedal assembly will be disassembled for paint or powdercoat. While the assembly is simply the reversal of removal, the purpose of this manual is to help the end user reassemble the unit with minimal frustration. Please DO NOT powdercoat the pedal bushings. For this reason it is recommended the pedal arms be painted. Assembly Procedures Brake & Clutch Pedal Assembly Rev0 MJ 05/13/

35 1. Insert bronze bushings (PN ) into the tube welded in the frame rail and slide the pivot shaft into place (shaft orientation is not critical). 2. Slide one pedal spacer (PN ) over each end of the pivot shaft. 3. Insert two bronze bushings (PN ) into the brake pedal arm sleeve (PN ) and slide the assembly over the pivot shaft. 4. Insert one pedal spacer (PN ) over the pivot shaft, in between the brake pedal assembly and urethane/bronze bushed support bearing, then slide the pivot shaft through the support bearing. 5. Slide two wave spring washers (PN ) onto the pivot shaft. 6. Insert the clutch master cylinder actuator arm (PN ) onto the pivot shaft. 7. Secure the actuator arm with the aluminum countersunk washer (PN ) and countersunk fastener (PN ). 8. Insert the clutch pedal (PN ) onto the pivot shaft. 9. Slide one pedal spacer (PN ) over the pivot shaft. 10. Secure the clutch pedal to the shaft using the aluminum countersunk washer (PN ) and countersunk screw (PN ). 11. Attach the master cylinders (with rod ends on the pushrods) to the frame bracket. Attach the rod ends to the brake and clutch pedal. Re-clocking the clutch pedal and actuator arm may be necessary to ensure proper pedal position and full travel. 12. When proper pedal travel has been confirmed, remove each countersunk screw and apply red or blue Loctite, and torque to 25 lb-ft. 13. Slide pedal pads over pad bracket. Attach brackets to pedal arms using the supplied #10 countersunk screws. Please note: Due to variances in height between the chassis and cab, some may need to enlarge the opening of the pedal pass-through holes. The pedal spacers (PN ) may be stacked on either side of the pedal for left/right alignment. 35 Rev0 MJ 05/13/

36 36 Assembly Procedures Brake Pedal Assembly w/o Clutch 1. Insert bronze bushings (PN ) into the tube welded in the frame rail and slide the pivot shaft into place (shaft orientation is not critical). 2. Slide two wave spring washers (PN ) onto the pivot shaft (outside of frame rail) and attach snap ring (PN ) to end of pivot shaft. 3. Attach aluminum countersunk washer (PN ) to pivot shaft (outside of frame rail) and secure with countersunk screw (PN ) with red or blue Loctite, torque to 25 lb-ft. 4. Slide one pedal spacer (PN ) over the pivot shaft (inside of frame rail) 5. Insert two bronze bushings (P ) into brake pedal assembly (PN ) and slide over pivot shaft. 6. Slide pedal spacer (PN ) over pivot shaft. 7. Attach an aluminum countersunk washer (PN to pivot shaft and secure with countersunk screw (PN ) with red or blue Loctite, torque to 25 lb-ft. 8. Slide pedal pads over pad bracket. Attach brackets to pedal arms using the supplied #10 countersunk screws. Please note: Due to variances in height between the chassis and cab, some may need to enlarge the opening of the pedal pass-through holes. The pedal spacers (PN ) may be stacked on either side of the pedal for left/right alignment. Pedal Geometry & Hydraulic Info Both brake and clutch pedals utilize a 6:1 ratio to work well with most manual brake applications, as well as those using a 7 power brake booster. Most Wilwood brakes will work best with a ¾ to 7/8 bore master cylinder. Most hydraulic throwout bearings also work well with a ¾ bore master cylinder. Rev0 MJ 05/13/

37 37 Figure 1 - Attaching pedal pad to arm (Automatics similar) Rev0 MJ 05/13/

38 38 Figure 2 - Attaching master cylinders to frame mount Rev0 MJ 05/13/

39 39 Figure 3 - Attaching linkage (Disregard clutch linkage for automatics) Rev0 MJ 05/13/

40 40 Figure 4 - Pedal assembly (Manual Transmissions) Rev0 MJ 05/13/

41 41 Figure 5 Pedal Assembly Bill of Materials (Manual Transmission) Rev0 MJ 05/13/

42 42 Figure 6 Pedal Assembly (Automatic Transmission) Rev0 MJ 05/13/

43 43 Figure 7 - Pedal Assembly Bill of Materials (Automatic Transmission) ART MORRISON ENTERPRISES, INC TH STREET EAST FIFE, WASHINGTON, (800) (253) FAX (253)

44 44 Optional Equipment: LS Polyurethane Motor Mount Kit ART MORRISON ENTERPRISES, INC TH STREET EAST FIFE, WASHINGTON, (800) (253) FAX (253)

45 45 Optional Equipment: Coyote Rubber Motor Mount Kit Rev0 MJ 05/13/

46 46 Optional Equipment: LS Rubber Motor Mount Kit Rev0 MJ 05/13/

47 47 Optional equipment: 289/302/351W Rubber Motor Mount Kit Rev0 MJ 05/13/

48 48 Optional Equipment: Axle Housing Vent Kit Rev0 MJ 05/13/

49 49 Fastener Information & Torque Specifications AME is now offering an upgraded line of fasteners to come standard with every AME chassis to provide you with OEM quality grade fasteners for your street machine or race car. AME s chassis fasteners utilize a Magni Coating for increased corrosion resistance, flanged nuts and bolts for a greater load distribution, and distorted thread locking nuts for a larger resistance to loosening forces. Advantages: Resists corrosion up to 13x s longer than typical Zinc plated fasteners Magni coating meets several OEM manufacturer specifications including GM, Ford, and Chrysler Flanged fasteners provide a larger load distribution on the mating surface typically eliminating washers Distorted thread lock nuts provide the increased resistance to loosing forces from vibration and movement Identification: Magni coated fasteners consist of a Zinc base coat with an Aluminum top coat which results in a gray-silver finish Distorted Thread locking nuts with flanges have a distinctive tapered top edge and the locking nuts without flanged contain a hexagon impression on the side. Instructions: All AME chassis are assembled with the Magni coated flanged bolts, but use Zinc plated jam nuts for ease of assembly and mock-up during the building process The matching lock nuts are provided loose in a bag with the chassis components Upon final assembly only replace the jam nuts with the Magni Distorted Thread Lock Nuts Installation of these nuts requires a significant increase in effort compared to other lock nuts. They will generate some amount of heat during installation due to the interference fit. Avoid reinstallation as much as possible. Like nylon-lock nuts, the locking capability wears slightly every use, therefore if the tightening effort dramatically decreases, replace the nut Reference AME torque specifications for final torque values Contact AME for any replacement pieces of hardware or to retro-fit your previously purchased chassis with the upgraded fasteners ART MORRISON ENTERPRISES, INC TH STREET EAST FIFE, WASHINGTON, (800) (253) FAX (253)

50 ART MORRISON ENTERPRISES, INC TH STREET EAST FIFE, WASHINGTON, (800) (253) FAX (253)

51 ART MORRISON ENTERPRISES, INC TH STREET EAST FIFE, WASHINGTON, (800) (253) FAX (253)